CN117597834A

CN117597834A - Circuit connection device, rotary electric machine device, and method for manufacturing circuit connection device

Info

Publication number: CN117597834A
Application number: CN202180099106.XA
Authority: CN
Inventors: 铃木淳也; 大西善彦; 园田功
Original assignee: Mitsubishi Electric Corp
Current assignee: Mitsubishi Electric Corp
Priority date: 2021-07-28
Filing date: 2021-07-28
Publication date: 2024-02-23
Also published as: EP4379965A4; JP7442745B2; WO2023007598A1; JPWO2023007598A1; US20240258872A1; EP4379965A1

Abstract

The circuit connection device includes: a connector having a press-fit terminal; a circuit board having a terminal through hole pressed into the press-fit terminal; a terminal arrangement member having a terminal guide portion formed with a guide through hole for guiding the press-fit terminal toward the terminal through hole; and a heat sink having an opening for accommodating the terminal guide portion therein, wherein a first positioning protrusion is formed on one of the connector and the heat sink, a first positioning recess is formed on the other of the connector and the heat sink, a second positioning protrusion is formed on one of the circuit board and the terminal arrangement member, a second positioning recess is formed on the other of the circuit board and the terminal arrangement member, a third positioning protrusion is formed on one of the heat sink and the terminal arrangement member, and a third positioning recess is formed on the other of the heat sink and the terminal arrangement member.

Description

Circuit connection device, rotary electric machine device, and method for manufacturing circuit connection device

Technical Field

The present disclosure relates to a circuit connection device, a rotating electrical machine device, and a method of manufacturing the circuit connection device.

Background

Conventionally, as a control unit of a rotating electrical machine device, a circuit connection device having a circuit board and a connector has been used. In connection of a circuit board and a connector, a press-fit terminal is sometimes used. By pressing the press-fit terminals of the connector into the terminal through-holes of the circuit board, electrical connection between the circuit board and the connector can be ensured without soldering or the like.

In order to cool electronic components mounted on a circuit board, a heat sink is sometimes provided. In the case where the heat sink is provided between the circuit board and the connector, it is difficult to insert the press-fit terminal into the terminal through-hole due to the spaced-apart interval between the circuit board and the connector. In patent document 1, a terminal arrangement member is mounted on a circuit board so that a press-fit terminal is easily inserted into a terminal through hole. The terminal arrangement member has a guide through hole for guiding the press-fit terminal to the terminal through hole. In order to facilitate insertion of the press-fit terminal into the guide through hole, an insertion guide hole that is inclined so as to expand in diameter toward the opening end of the connector side is provided at the connector-side end of the guide through hole.

Prior art literature

Patent literature

Patent document 1: japanese patent laid-open publication No. 2005-302614

Disclosure of Invention

Technical problem to be solved by the invention

In the structure of patent document 1, when the relative position of the connector and the circuit board is greatly deviated from the reference position at the time of assembling the circuit connection device, there is a possibility that the tip of the press-fit terminal collides with the guide through hole of the terminal arrangement member or its periphery. As a result, the quality of the circuit connection device such as the crimp terminal may be degraded.

In order to prevent collision of the press-fit terminal with the guide through hole, it is considered to increase the diameter of the opening of the guide through hole. In addition, by reducing the inclination angle of the insertion guide hole, buckling of the press-fit terminal can be prevented. However, if the diameter of the opening of the guide through hole is increased, the arrangement interval of the guide through hole needs to be increased, and the arrangement interval of the press-fit terminal and the terminal through hole also becomes large. In addition, if the inclination angle of the insertion guide hole is reduced, the thickness of the terminal alignment member needs to be increased in order to form a through hole for a terminal of a desired size. As a result, the circuit connection device is enlarged.

The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a circuit connection device, a rotating electrical machine device, and a method for manufacturing the circuit connection device, which can achieve miniaturization and improve assemblability.

Technical means for solving the technical problems

The circuit connection device according to the present disclosure includes: a connector having a connection terminal connected to the outside and a press-fit terminal connected to the connection terminal; a circuit board having a terminal through hole pressed into the press-fit terminal; a terminal arrangement member which is arranged between the connector and the circuit board, is fixed to the circuit board, and has a terminal guide portion formed with a guide through hole for guiding the press-fit terminal to the terminal through hole; and a heat sink to which the circuit board is fixed on a first surface, the connector is fixed on a second surface opposite to the first surface, the heat sink has an opening that penetrates from the first surface to the second surface and accommodates the terminal guide portion therein, a first positioning protrusion is formed on one of the connector and the heat sink, a first positioning recess that fits the first positioning protrusion is formed on the other of the connector and the heat sink, a second positioning protrusion is formed on one of the circuit board and the terminal arrangement member, a second positioning recess that fits the second positioning protrusion is formed on the other of the circuit board and the terminal arrangement member, a third positioning protrusion is formed on one of the heat sink and the terminal arrangement member, and a third positioning recess that fits the third positioning protrusion is formed on the other of the heat sink and the terminal arrangement member.

The rotating electrical machine device according to the present disclosure includes: a rotating electric machine; and the circuit connection means for controlling the rotating electrical machine.

A method of manufacturing a circuit connection device according to the present disclosure is a method of controlling a circuit connection device including: a connector having a connection terminal connected to the outside and a press-fit terminal connected to the connection terminal; a circuit board having a terminal through hole pressed into the press-fit terminal; a terminal arrangement member which is arranged between the connector and the circuit board, is fixed to the circuit board, and has a terminal guide portion formed with a guide through hole for guiding the press-fit terminal to the terminal through hole; and a heat sink to which the circuit board is fixed on a first surface, the connector is fixed on a second surface opposite to the first surface, the heat sink has an opening that penetrates from the first surface to the second surface and accommodates the terminal guide portion therein, a first positioning protrusion is formed on one of the connector and the heat sink, a first positioning recess that fits into the first positioning protrusion is formed on the other of the connector and the heat sink, a second positioning protrusion is formed on one of the circuit board and the terminal arrangement member, a second positioning recess that fits into the second positioning protrusion is formed on the other of the circuit board and the terminal arrangement member, a third positioning protrusion is formed on one of the heat sink and the terminal arrangement member, and a third positioning recess that fits into the third positioning protrusion is formed on the other of the heat sink and the terminal arrangement member, the manufacturing method of the circuit connection device includes: a first step of fixing the terminal arrangement member to the circuit board by fitting the second positioning protrusion into the second positioning recess; a second step of fitting the third positioning protrusion and the third positioning recess, accommodating the terminal guide in the opening, and fixing the terminal arrangement member to the heat sink; and a third step of fitting the first positioning protrusion into the first positioning recess, inserting the press-fit terminal into the guide through hole, and pressing the terminal through hole to fix the connector to the heat sink.

Effects of the invention

According to the present disclosure, a circuit connection device, a rotating electrical machine device, and a method for manufacturing the circuit connection device, which can be miniaturized and have improved assemblability, can be provided.

Drawings

Fig. 1 is a schematic cross-sectional view of a rotating electrical machine device according to embodiment 1.

Fig. 2 is a perspective view of the circuit connection device according to embodiment 1.

Fig. 3 is a perspective view of the connector according to embodiment 1.

Fig. 4 is a perspective view of the connector according to embodiment 1.

Fig. 5 is a perspective view of the circuit board according to embodiment 1.

Fig. 6 is a perspective view of a terminal arrangement member according to embodiment 1.

Fig. 7 is a perspective view of a terminal arrangement member according to embodiment 1.

Fig. 8 is a perspective view of a radiator according to embodiment 1.

Fig. 9 is a diagram illustrating a first step of a method for manufacturing a circuit connection device according to embodiment 1.

Fig. 10 is a diagram illustrating a second step of the method for manufacturing the circuit connection device according to embodiment 1.

Fig. 11 is a diagram illustrating a third step of the method for manufacturing the circuit connection device according to embodiment 1.

Fig. 12 is a diagram illustrating a third step of the method for manufacturing the circuit connection device according to embodiment 1.

Fig. 13 is a perspective view of a connector according to embodiment 2.

Fig. 14 is a schematic cross-sectional view of the circuit connection device according to embodiment 2.

Fig. 15 is a perspective view of a connector according to embodiment 3.

Fig. 16 is a schematic cross-sectional view of the circuit connection device according to embodiment 3.

Fig. 17 is a perspective view of a connector according to embodiment 4.

Fig. 18 is a plan view of a connector according to embodiment 4.

Detailed Description

Embodiment 1.

The circuit connection device 2 and the rotating electrical machine device a according to embodiment 1 will be described below with reference to the drawings.

Fig. 1 is a schematic cross-sectional view of a rotary electric machine device a. The rotary electric machine apparatus a includes a rotary electric machine 1 of a multiphase winding type and a circuit connection device 2 that controls the rotary electric machine 1.

The rotary electric machine 1 mainly includes a rotary shaft 11, a rotor 12, a stator 13, a housing 14, a cover 15, windings 16, an annular wiring portion 17, wiring terminals 18, and first and second bearings 19a and 19 b. Fig. 1 is a cross-sectional view of a rotating electrical device a along a rotating shaft 11. In fig. 1, the lower side of the drawing is the output side of the rotary shaft 11, and the upper side of the drawing is the non-output side of the rotary shaft 11.

The rotation shaft 11 extends along the axis. The rotor 12 is fixed to the rotary shaft 11. A plurality of pairs of permanent magnets (not shown) are disposed on the outer peripheral surface of the rotor 12. These permanent magnets constitute the excitation pole.

The stator 13 is provided so as to surround the outer periphery of the rotor 12. The stator 13 is fixed to the inner surface of the housing 14. A gap is formed between the outer peripheral surface of the rotor 12 and the inner peripheral surface of the stator 13. The air gap is formed over the entire circumference in the circumferential direction around the axis of the rotary shaft 11.

The housing 14 has a cylindrical shape. The housing 14 accommodates the rotary shaft 11, the rotor 12, and the stator 13. The cover 15 covers the lower end of the housing 14. The upper end of the housing 14 is covered with a heat sink 5 of the circuit connection device 2 described later.

The winding 16 is wound around the stator 13. The windings 16 include U-phase windings, V-phase windings, and W-phase windings. The annular wiring portion 17 is disposed on the non-output side (i.e., the upper side in fig. 1) of the rotary shaft 11 with respect to the winding 16. The annular wiring portion 17 is connected to an end portion of the winding 16 by TIG welding or the like.

The wiring terminal 18 is connected to the annular wiring portion 17. The wiring terminal 18 extends from the annular wiring portion 17 to the non-output side of the rotary shaft 11 through the heat sink 5. The wiring terminal 18 is electrically connected to an end portion of the winding 16 via the annular wiring portion 17. The wiring terminal 18 is composed of 3 conductors. These 3 conductors are connected to the wiring terminals of the U-phase winding, the wiring terminals of the V-phase winding, and the wiring terminals of the W-phase winding of the winding 16, respectively. The wiring terminals 18 are connected to the circuit board 3 of the circuit connection device 2 described later by soldering or the like.

A first bearing 19a is provided at the end portion (upper end portion in fig. 1) of the rotation shaft 11 on the non-output side. A second bearing 19b is provided at an output-side end (lower end in fig. 1) of the rotary shaft 11. The first bearing 19a and the second bearing 19b rotatably support the rotary shaft 11.

The first bearing 19a is fixed to the radiator 5. The second bearing 19b is fixed to the cover 15.

The sensor rotor 21 is fixed to the end surface of the rotary shaft 11 on the non-output side. The sensor rotor 21 rotates with the rotation of the rotation shaft 11. The sensor rotor 21 is provided with 1 or more pairs of permanent magnets.

Fig. 2 is a perspective view of the circuit connection device 2 according to embodiment 1.

As shown in fig. 1 and 2, the circuit connection device 2 includes a circuit board 3, a connector 4, a heat sink 5 provided between the circuit board 3 and the connector 4, a terminal arrangement member 6 provided between the circuit board 3 and the connector 4 and fixed to the circuit board 3, and a cover 7 covering the circuit board 3 and the heat sink 5. Fig. 2 shows the cover plate 7 removed. In the present embodiment, the circuit connection device 2 is a control unit that controls a current flowing through the winding 16 of the rotating electrical machine 1.

Fig. 3 and 4 are perspective views of the connector 4.

As shown in fig. 3 and 4, the connector 4 includes: a main body 40 having a first surface 4a and a second surface 4b, a power terminal 41 (connection terminal), a signal terminal 42 (connection terminal), a power-side case 43, a signal-side case 44, a plurality of press-fit terminals 45, and a pair of first positioning protrusions 46. As shown in fig. 1, the first surface 4a is a surface on the upper side of the connector 4 (the output side of the rotary shaft 11), and the second surface 4b is a surface on the lower side of the connector 4 (the non-output side of the rotary shaft 11). Fig. 3 is a view of the connector 4 from the first surface 4a side. Fig. 4 is a view of the connector 4 from the second surface 4b side.

The power supply terminal 41 and the signal terminal 42 protrude from the second face 4b of the main body portion 40. The power supply terminal 41 is connected to an external power supply (battery). The signal terminal 42 is connected to an external sensor or the like. As shown in fig. 1, the power supply terminal 41 and the signal terminal 42 extend toward the output side of the rotary shaft 11.

In the present embodiment, the power supply terminal 41 and the signal terminal 42 have different shapes, but terminals having the same shape may be used as the power supply terminal 41 and the signal terminal 42. As the power supply terminal 41 and the signal terminal 42, terminals of 3 or more shapes may be used.

The power supply terminal 41 and the signal terminal 42 extend toward the output side of the rotary shaft 11, but may extend toward the non-output side of the rotary shaft 11.

The power source side case 43 is provided on the second surface 4b of the main body 40. The power supply side case 43 is a container having an opening, and accommodates the power supply terminal 41 therein. The power source side case 43 is integrally formed with the main body portion 40.

The signal-side housing 44 is provided on the second surface 4b of the main body 40. The signal-side case 44 is a container having an opening, and accommodates the signal terminals 42 therein. The signal-side housing 44 is integrally formed with the main body portion 40.

In the present embodiment, the power supply side case 43 and the signal side case 44 are provided as separate containers, but the power supply side case 43 and the signal side case 44 may be formed of a single container. The power source side case 43 and the signal side case 44 may be formed of 3 or more containers. That is, the power supply terminal 41 and the signal terminal 42 may be housed in a single container, or may be housed in 3 or more containers.

The plurality of press-fit terminals 45 are provided corresponding to the power supply terminal 41 and the signal terminal 42, respectively. The press-fit terminals 45 are connected to the corresponding power supply terminals 41 or signal terminals 42. The press-fit terminals 45 extend from the corresponding power supply terminals 41 or signal terminals 42, protruding from the first face 4a of the main body portion 40. As shown in fig. 1 and 2, the press-fit terminals 45 extend toward the circuit substrate 3. The press-fit terminals 45 extend toward the non-output side of the rotary shaft 11.

In the present embodiment, the bonding terminal 45 extends to the opposite side to the extending direction of the power supply terminal 41 and the signal terminal 42, but the bonding terminal 45 may extend in a direction orthogonal to the extending direction of the power supply terminal 41 and the signal terminal 42.

The press-fit terminal 45 is integrally formed in an elongated plate shape. A pressing portion 45a is formed at the front end portion of the pressing terminal 45. The width (maximum width) of the nip portion 45a is larger than the width of the other portion of the nip terminal 45. Holes are formed in the nip portion 45a, whereby the nip portion 45a can be elastically deformed.

The first positioning protrusion 46 protrudes from the first surface 4a of the main body 40. The first positioning protrusion 46 is formed in a substantially cylindrical shape as a whole. A tapered surface is provided at the tip end of the first positioning protrusion 46. That is, the tip end portion of the first positioning protrusion 46 is tapered toward the tip end of the first positioning protrusion 46.

The first positioning protrusion 46 extends parallel to the press-fit terminal 45. The pair of first positioning protrusions 46 is provided so as to sandwich the plurality of press-fit terminals 45. The length of the first positioning protrusion 46 (i.e., the length of the portion of the first positioning protrusion 46 protruding from the first surface 4 a) is shorter than the length of the press-fit terminal 45 (i.e., the length of the portion of the press-fit terminal 45 protruding from the first surface 4 a). Therefore, the press-fit terminal 45 protrudes upward from the tip end of the first positioning protrusion 46.

Fig. 5 is a perspective view of the circuit board 3.

As shown in fig. 1 and 5, the circuit board 3 has a first surface 3a and a second surface 3b. The first surface 3a is a surface on the upper side (output side of the rotary shaft 11) of the circuit board 3, and the second surface 3b is a surface on the lower side (non-output side of the rotary shaft 11) of the circuit board 3. Fig. 5 is a view of the circuit board 3 from the second surface 3b side.

The circuit board 3 is a printed wiring board. A small electronic component such as a rotation sensor 31, a microcomputer 32, a shunt resistor 33, a switching element 34, and a large electronic component such as a filter capacitor 36 are mounted on the second surface 3b of the circuit board 3. The microcomputer 32, the shunt resistor 33, and the switching element 34 are electronic components that generate heat. The microcomputer 32, the shunt resistor 33, and the switching element 34 are collectively referred to as a heat generating component 35.

The rotation sensor 31 is a magnetic sensor. As shown in fig. 1, the rotation sensor 31 is arranged coaxially with the sensor rotor 21 provided on the end surface of the rotation shaft 11 on the non-output side. The sensor rotor 21 and the rotation sensor 31 face each other with a gap therebetween. The rotation sensor 31 detects a change in the magnetic field from the permanent magnet of the sensor rotor 21 rotating together with the rotation shaft 11 and converts it into an electric signal. The sensor rotor 21 and the rotation sensor 31 detect the rotation state of the rotary shaft 11. As the rotation sensor 31, a resolver, a hall sensor, an optical sensor, or the like may be used.

Referring back to fig. 5, a plurality of terminal through holes 37 are formed in the circuit board 3. The terminal through-hole 37 penetrates the circuit board 3 from the first surface 3a to the second surface 3b. The plurality of terminal through holes 37 are provided at positions corresponding to the plurality of press-fit terminals 45. The inner diameter of the terminal through hole 37 is smaller than the width (maximum width) of the pressing portion 45 a. The plurality of press-fit terminals 45 are press-fitted into the plurality of terminal through-holes 37.

A conductive layer is formed on the inner surface of the terminal through hole 37. By pressing the press-fit terminal 45 into the terminal through-hole 37, the press-fit terminal 45 is electrically connected in contact with the conductive layer on the inner surface of the terminal through-hole 37. By using the press-fit terminals 45, the circuit board 3 and the connector 4 can be electrically connected without soldering or the like. Therefore, the manufacturing of the circuit connection device 2 becomes easy, and the manufacturing time can be shortened.

A pair of circuit board side through holes 38 (second positioning recesses) are formed in the circuit board 3. The circuit board-side through hole 38 penetrates the circuit board 3 from the first surface 3a to the second surface 3b. The pair of circuit board side through holes 38 are provided so as to sandwich the plurality of terminal through holes 37.

Fig. 6 and 7 are perspective views of the terminal arrangement member 6.

As shown in fig. 6 and 7, the terminal arrangement member 6 includes a main body portion 60 having a first face 6a and a second face 6b, a pair of second positioning protrusions 61, a pair of third positioning protrusions 62, and a terminal guide portion 63. The first surface 6a is a surface on the upper side (output side of the rotary shaft 11) of the terminal arrangement member 6, and the second surface 6b is a surface on the lower side (non-output side of the rotary shaft 11) of the terminal arrangement member 6. Fig. 6 is a view of the terminal arrangement member 6 from the first surface 6a side. Fig. 7 is a view of the terminal arrangement member 6 from the second surface 6b side.

The terminal guide 63 is a box-like member. The terminal guide 63 is mounted on the second surface 6b of the main body 60. The surface of the terminal guide 63 opposite to the surface mounted on the main body 60 is referred to as a lower surface 6c.

A plurality of guide through holes 64 are formed in the body 60 and the terminal guide 63. The guide through hole 64 penetrates the body 60 and the terminal guide 63 in the up-down direction. That is, the guide through hole 64 penetrates the body 60 and the terminal guide 63 from the first surface 6a to the lower surface 6c. The plurality of guide through holes 64 are provided at positions corresponding to the plurality of terminal through holes 37. The guide through-hole 64 communicates with the terminal through-hole 37. The inner diameter of the guide through hole 64 is larger than the inner diameter of the terminal through hole 37. The inner diameter of the guide through hole 64 is larger than the width (maximum width) of the nip portion 45 a. The guide through-holes 64 guide the press-fit terminals 45 toward the terminal through-holes 37.

At the end portion of the guide through hole 64 on the lower surface 6c side, an insertion guide hole 65 is provided that is inclined so as to expand in diameter toward the opening end on the connector 4 side (i.e., toward the lower surface 6c side).

The second positioning protrusion 61 protrudes from the first surface 6a of the main body 60. The second positioning protrusion 61 is formed in a substantially cylindrical shape as a whole. A tapered surface is provided at the tip end of the second positioning protrusion 61. That is, the tip end portion of the second positioning protrusion 61 is tapered toward the tip end of the second positioning protrusion 61. The pair of second positioning protrusions 61 are provided so as to sandwich the plurality of guide through holes 64.

The second positioning protrusion 61 is provided at a position corresponding to the circuit board side through hole 38. The circuit board side through hole 38 and the second positioning protrusion 61 are coaxially arranged. The second positioning protrusion 61 is inserted into the circuit board side through hole 38.

The third positioning protrusion 62 protrudes from the second surface 6b of the main body 60. The third positioning protrusion 62 is formed in a substantially cylindrical shape as a whole. A tapered surface is provided at the tip end of the third positioning protrusion 62. That is, the tip end portion of the third positioning protrusion 62 is tapered toward the tip end of the third positioning protrusion 62. The pair of third positioning protrusions 62 are provided so as to sandwich the terminal guide 63.

Fig. 8 is a perspective view of the heat sink 5.

As shown in fig. 8, the heat sink 5 has: a main body 50 having a first surface 5a and a second surface 5 b; a heat radiation section 51; a large-sized component housing portion 53; a through hole 54 for a rotation shaft; an opening 55; and a pair of radiator-side through holes 56 (first positioning concave portion, third positioning concave portion). As shown in fig. 1, the first surface 5a is a surface on the upper side (output side of the rotary shaft 11) of the heat sink 5. The second surface 5b is a surface on the lower side (non-output side of the rotary shaft 11) of the heat sink 5. Fig. 8 is a view of the heat sink 5 from the first surface 5a side.

As shown in fig. 1, the heat sink 5 covers the upper end of the housing 14. The heat sink 5 functions as a cover that closes the inside of the rotating electrical machine 1. Further, the circuit board 3 and the terminal arrangement member 6 are mounted on the first surface 5a of the heat sink 5. A connector 4 is mounted on the second face 5b of the heat sink 5.

Returning to fig. 8, the heat dissipation portion 51 is a recess provided on the first surface 5a of the main body portion 50. The heat sink 51 is provided at a position corresponding to the heat generating component 35 mounted on the circuit board 3. The heat dissipation portion 51 is coated with heat dissipation lubricant 52 (see fig. 1). When the circuit substrate 3 is mounted on the heat sink 5, the heat generating component 35 is closely covered with the heat dissipation lubricating oil 52. Thereby, the heat of the heat generating component 35 is radiated to the radiator 5 via the heat radiation lubricating oil 52.

The large-sized component housing portion 53 is a recess provided on the first surface 5a of the main body portion 50. The large-sized component housing 53 is provided at a position corresponding to a large-sized electronic component such as the filter capacitor 36 mounted on the circuit board 3. By providing the large-sized component housing portion 53, interference between the heat sink 5 and the large-sized electronic component such as the filter capacitor 36 can be prevented.

The rotation shaft through-hole 54 penetrates the body 50 from the first surface 5a to the second surface 5b. As shown in fig. 1, the through-hole 54 for the rotation shaft is provided at a position corresponding to the rotation shaft 11. The non-output side end of the rotary shaft 11 is inserted into the rotary shaft through hole 54. The first bearing 19a is disposed in the through hole 54 for the rotation shaft. Inside the through hole 54 for the rotation shaft, the sensor rotor 21 faces the rotation sensor 31, and the rotation state of the rotation shaft 11 can be detected by the sensor rotor 21 and the rotation sensor 31.

The opening 55 penetrates the body 50 from the first surface 5a to the second surface 5b. The opening 55 is provided at a position corresponding to the terminal guide 63. A terminal guide 63 is disposed inside the opening 55.

The radiator-side through hole 56 penetrates the body portion 50 from the first surface 5a to the second surface 5b. The pair of radiator-side through holes 56 are provided so as to sandwich the opening 55. The radiator-side through hole 56 is provided at a position corresponding to the first positioning protrusion 46 and the third positioning protrusion 62. The radiator-side through hole 56, the first positioning projection 46, and the third positioning projection 62 are coaxially arranged. The first positioning protrusion 46 is inserted into the radiator-side through hole 56 from the second surface 5b side, and the third positioning protrusion 62 is inserted into the radiator-side through hole 56 from the first surface 5a side. The inner diameter of the radiator-side through hole 56 is set so that the first positioning projection 46 and the third positioning projection 62 can be pressed into the radiator-side through hole 56.

The height of the main body 50 (i.e., the length from the first surface 5a to the second surface 5b of the main body 50) is greater than the sum of the length of the first positioning protrusion 46 (i.e., the length of the portion of the first positioning protrusion 46 protruding from the first surface 4 a) and the length of the third positioning protrusion 62 (i.e., the length of the portion of the third positioning protrusion 62 protruding from the second surface 6 b). Therefore, even when both the first positioning protrusion 46 and the third positioning protrusion 62 are inserted into the radiator-side through hole 56, the first positioning protrusion 46 and the third positioning protrusion 62 can be prevented from colliding.

In addition, the height of the main body portion 50 is longer than the height of the terminal guide portion 63 (i.e., the length from the second face 6b to the lower face 6c of the terminal guide portion 63). Accordingly, the entire terminal guide 63 is accommodated in the opening 55.

Next, a method for manufacturing the circuit connection device 2 according to embodiment 1 will be described with reference to fig. 9 to 12. The method of manufacturing the circuit connection device 2 includes a first step of mounting the terminal arrangement member 6 on the circuit substrate 3, a second step of mounting the circuit substrate 3 and the terminal arrangement member 6 on the heat sink 5, and a third step of mounting the connector 4 on the heat sink 5. In the following description, a direction along a plane perpendicular to the extending direction of the press-fit terminal 45 (i.e., the extending direction of the first positioning protrusion 46) is referred to as a horizontal direction.

Fig. 9 is a diagram illustrating the first step.

In the first step, the circuit board 3 is first arranged with the second surface 3b on the upper side. The terminal arrangement member 6 is disposed so that the second surface 3b of the circuit board 3 faces the first surface 6a of the main body 60. The second positioning protrusion 61 of the terminal arrangement member 6 is inserted into the circuit board side through hole 38 of the circuit board 3. Since the tip end portion of the second positioning protrusion 61 is tapered, the second positioning protrusion 61 can be smoothly inserted into the circuit board side through hole 38. By inserting the second positioning protrusion 61 into the circuit board side through hole 38, the position of the terminal arrangement member 6 in the horizontal direction with respect to the circuit board 3 is adjusted. Thus, the center of the terminal through hole 37 and the center of the guide through hole 64 are aligned so that the horizontal positions of the terminal through hole 37 and the guide through hole 64 are aligned, and the terminal through hole 37 and the guide through hole 64 communicate with each other.

Fig. 10 is a diagram illustrating the second step.

In the second step, the heat sink 5 is first arranged with the first surface 5a on the upper side. In the first step, the circuit board 3 and the terminal arrangement member 6 fixed to each other are vertically reversed, and the circuit board 3 and the terminal arrangement member 6 are disposed so that the first surface 5a of the main body 50 faces the second surface 3b of the circuit board 3. The third positioning protrusion 62 of the terminal arrangement member 6 is inserted into the radiator-side through hole 56 of the radiator 5. Since the tip end portion of the third positioning protrusion 62 is tapered, the third positioning protrusion 62 can be smoothly inserted into the radiator-side through hole 56. At this time, the terminal guide 63 is inserted into the inside of the opening 55. The main body portion 60 of the terminal arrangement member 6 is sandwiched between the circuit board 3 and the heat sink 5. By inserting the third positioning protrusion 62 into the heat sink-side through hole 56, the positions of the circuit board 3 and the terminal arrangement member 6 in the horizontal direction with respect to the heat sink 5 are adjusted. Thus, the heat radiating portion 51 (heat radiating lubricant 52) is aligned with the heat generating component 35 in the horizontal direction so that the heat radiating portion 51 (heat radiating lubricant 52) faces the heat generating component 35. The large component housing 53 is aligned with the filter capacitor 36 in the horizontal direction so that the large component housing 53 faces the filter capacitor 36. The rotation shaft through-hole 54 is aligned with the horizontal position of the rotation sensor 31, so that the positional displacement of the rotation sensor 31 can be suppressed, and the rotation state of the rotation shaft 11 can be detected with high accuracy.

Then, a load is applied to the circuit board 3 in a direction orthogonal to the first surface 3a of the circuit board 3, and the circuit board 3 is pressed into the heat sink 5. Thereby, the third positioning protrusion 62 is pressed into and fixed to the radiator-side through hole 56. At this time, the heat radiation lubricant 52 applied to the heat radiation portion 51 of the heat radiator 5 is squeezed and expanded, and the heat generating component 35 is tightly covered with the heat radiation lubricant 52. When the third positioning protrusion 62 is pressed, the heat dissipation lubricant 52 can be squeezed and expanded, and therefore the assembling process can be simplified. The filter capacitor 36 is disposed inside the large-sized component housing 53. The rotation sensor 31 is disposed inside the rotation shaft through hole 54.

The circuit board 3 and the terminal arrangement member 6 are fixed to the heat sink 5 by screw tightening in a state where the circuit board 3 is pressed against the heat sink 5. The fixing of the circuit board 3 and the terminal arrangement member 6 to the heat sink 5 is not limited to screw fastening, and may be fixing by an adhesive, fixing by fusion bonding, fixing by soldering, fixing by welding, press-bonding, or the like.

Fig. 11 and 12 are diagrams illustrating the third step.

In the third step, the circuit board 3, the terminal arrangement member 6, and the heat sink 5 fixed to each other in the second step are vertically reversed, and the circuit board 3, the terminal arrangement member 6, and the heat sink 5 are disposed so that the second surface 5b of the main body 50 is on the upper side. The connector 4 is arranged such that the second surface 5b of the main body 50 is opposite to the first surface 4a of the main body 40. The first positioning protrusion 46 of the connector 4 is inserted into the radiator-side through hole 56 of the radiator 5. Since the tip end portion of the first positioning protrusion 46 is tapered, the first positioning protrusion 46 can be smoothly inserted into the radiator-side through hole 56. By inserting the first positioning protrusion 46 into the radiator-side through hole 56, the horizontal positions of the connector 4 with respect to the radiator 5, the circuit board 3, and the terminal arrangement member 6 are adjusted. Thus, the positions of the press-fit terminals 45, the terminal through holes 37, and the guide through holes 64 in the horizontal direction are aligned so that the centers of the press-fit terminals 45, the center of the terminal through holes 37, and the center of the guide through holes 64 coincide with each other.

In this state, the connector 4 is further moved toward the heat sink 5, and the press-fit terminal 45 is inserted into the guide through hole 64.

Here, as shown in fig. 12, the length in the extending direction of the press-fit terminal 45 from the tip end of the first positioning protrusion 46 to the opening end of the radiator-side through hole 56 on the connector 4 side is L1, and if the length in the extending direction of the press-fit terminal 45 from the tip end of the press-fit terminal 45 to the opening end of the guide through hole 64 on the connector 4 side is L2, the length L1 is longer than the length L2. Therefore, at the stage when the first positioning protrusion 46 starts to be inserted into the heat sink-side through hole 56, the press-fit terminal 45 does not start to be inserted into the guide through hole 64. That is, by inserting the first positioning protrusion 46 into the heat sink-side through hole 56, the press-fit terminal 45 can be inserted into the guide through hole 64 after aligning the press-fit terminal 45 with the position of the guide through hole 64 in the horizontal direction. Therefore, the press-fit terminal 45 can be reliably and smoothly inserted into the guide through hole 64. Further, since the insertion guide hole 65 is formed in the guide through hole 64, the press-fit terminal 45 can be smoothly inserted into the guide through hole 64.

Then, the connector 4 is further moved toward the heat sink 5 side. The press-fit terminals 45 are inserted into the terminal through-holes 37 while being guided along the guide through-holes 64 and moved toward the circuit board 3.

Then, a load is applied to the connector 4 in a direction orthogonal to the second surface 4b of the connector 4, and the connector 4 is pushed into the heat sink 5. Thereby, the press-fit terminal 45 is pressed into the terminal through-hole 37 and fixed. The first positioning protrusion 46 is pressed into and fixed to the radiator-side through hole 56. Then, in a state where the connector 4 is pressed against the heat sink 5, the connector 4 is fixed to the heat sink 5 by screw tightening. The fixing of the connector 4 and the heat sink 5 is not limited to screw fastening, and may be fixing by an adhesive, fixing by welding, fixing by brazing, fixing by welding, press-bonding, or the like.

As described above, in the circuit connection device 2 according to the present embodiment, the connector 4 includes the power supply terminal 41 and the signal terminal 42 connected to the outside, and the press-fit terminal 45 connected to the power supply terminal 41 and the signal terminal 42. The circuit board 3 is formed with a terminal through-hole 37 into which the press-fit terminal 45 is press-fitted. The terminal arrangement member 6 is disposed between the connector 4 and the circuit board 3, and is fixed to the circuit board 3. The terminal arrangement member 6 has a terminal guide portion 63, and the terminal guide portion 63 is formed with a guide through hole 64, and the guide through hole 64 guides the press-fit terminal 45 toward the terminal through hole 37. The circuit board 3 is fixed to the first surface 5a of the heat sink 5, and the connector 4 is fixed to the second surface 5b, which is the surface opposite to the first surface 5 a. The heat sink 5 extends from the first surface 5a to the second surface 5b, and has an opening 55 for accommodating the terminal guide 63 therein. The connector 4 is formed with a first positioning protrusion 46, and the heat sink 5 is formed with a heat sink side through hole 56 fitted with the first positioning protrusion 46. The terminal arrangement member 6 is formed with a second positioning protrusion 61, and the circuit board 3 is formed with a circuit board side through hole 38 fitted with the second positioning protrusion 61. The terminal arrangement member 6 is formed with a third positioning protrusion 62, and the heat sink 5 is formed with a heat sink side through hole 56 fitted with the third positioning protrusion 62.

The method for manufacturing the circuit connection device 2 according to the present embodiment includes: a first step of fitting the second positioning protrusion 61 into the circuit board-side through hole 38 to fix the terminal arrangement member 6 to the circuit board 3; a second step of fitting the third positioning protrusion 62 into the heat sink-side through hole 56, accommodating the terminal guide 63 in the opening 55, and fixing the terminal arrangement member 6 to the heat sink 5; and a third step of fitting the first positioning protrusion 46 into the heat sink-side through hole 56, inserting the press-fit terminal 45 through the guide through hole 64, and pressing the terminal through hole 37, thereby fixing the connector 4 to the heat sink 5.

Since the press-fit terminals 45 are guided toward the terminal through-holes 37 by the guide through-holes 64, the press-fit terminals 45 can be reliably inserted into the terminal through-holes 37. Further, since the terminal guide portion 63 formed with the guide through hole 64 is disposed inside the opening portion 55 formed in the heat sink 5, the circuit connection device 2 can be prevented from being enlarged even if the terminal arrangement member 6 is provided.

The first positioning projection 46 is fitted into the radiator-side through hole 56, the second positioning projection 61 is fitted into the circuit board-side through hole 38, and the third positioning projection 62 is fitted into the radiator-side through hole 56. Thereby, the relative positions of the circuit board 3, the connector 4, the heat sink 5, and the terminal arrangement member 6 can be adjusted. Therefore, the circuit board 3, the connector 4, the heat sink 5, and the terminal arrangement member 6 can be assembled with each other easily and with high accuracy.

In the conventional terminal arrangement member, in order to prevent the press-fit terminals from colliding with the guide through holes due to the relative positional displacement of the connector and the circuit board, it is necessary to increase the diameter of the openings of the guide through holes, for example. In the circuit connection device 2 according to the present embodiment, the relative positions of the circuit board 3, the connector 4, the heat sink 5, and the terminal arrangement member 6 can be adjusted, and the press-fit terminals 45 can be inserted into the guide through holes 64 in a state where the positions of the press-fit terminals 45 and the guide through holes 64 are aligned. As a result, even if the size of the guide through hole 64 is not increased, the press-fit terminal 45 can be reliably inserted into the guide through hole 64, and the circuit connection device 2 can be prevented from being enlarged.

As described above, in the circuit connection device 2 according to the present embodiment, miniaturization can be achieved and assemblability can be improved.

In addition, the tip of the press-fit terminal 45 can be prevented from colliding with the guide through hole 64 or its surroundings, and the press-fit terminal 45 can be prevented from buckling. Thus, the high-quality circuit connection device 2 can be provided.

For example, in order to facilitate insertion of the press-fit terminal 45 into the guide through hole 64, an insertion guide hole 65 may be provided at an end portion of the guide through hole 64 on the connector 4 side. In addition, it is considered to prevent buckling of the press-fit terminal 45 by reducing the inclination angle of the insertion guide hole 65. Here, if the inclination angle of the insertion guide hole 65 is reduced, the thickness of the terminal guide portion 63 becomes large. However, in the circuit connection device 2 according to the present embodiment, since the terminal guide 63 is disposed inside the opening 55, even if the thickness of the terminal guide 63 is increased, it is possible to prevent the circuit connection device 2 from increasing in size as long as the thickness is smaller than the thickness of the heat sink 5.

The length L1 in the extending direction of the press-fit terminal 45 from the tip end of the first positioning protrusion 46 to the opening end of the heat sink-side through hole 56 on the connector 4 side is longer than the length L2 in the extending direction of the press-fit terminal 45 from the tip end of the press-fit terminal 45 to the opening end of the guide through hole 64 on the connector 4 side. Thus, the first positioning protrusion 46 can be inserted into the heat sink-side through hole 56 before the press-fit terminal 45 is inserted into the guide through hole 64, so that the press-fit terminal 45 and the guide through hole 64 are aligned. As a result, the press-fit terminals 45 can be inserted into the guide through holes 64 more reliably and smoothly.

The pair of first positioning protrusions 46 are provided so as to sandwich the press-fit terminal 45. The pair of second positioning protrusions 61 is provided so as to sandwich the guide through hole 64. The pair of third positioning protrusions 62 are provided so as to sandwich the guide through hole 64. This makes it possible to more accurately align the positions of the press-fit terminals 45, the guide through holes 64, and the terminal through holes 37.

Embodiment 2.

The circuit connection device 2 according to embodiment 2 will be described below with reference to the drawings. The same reference numerals are given to constituent elements having the same functions and actions as those of embodiment 1, and the description thereof will be omitted.

Fig. 13 is a perspective view of connector 104 according to embodiment 2. Fig. 14 is a schematic cross-sectional view of the circuit connection device 2 according to embodiment 2.

The connector 104 according to embodiment 2 has a plurality of press-fit terminals 145 instead of the plurality of press-fit terminals 45.

The press-fit terminal 145 includes a press-fit portion 45a and a position restricting portion 145b. The position regulating portion 145b is formed closer to the base end side than the press-fit portion 45 a. The width (maximum width) of the position restricting portion 145b is larger than the width (maximum width) of the nip 45 a. The width (maximum width) of the position regulating portion 145b is slightly smaller than the inner diameter of the guide through hole 64. When the press-fit terminal 145 is inserted through the guide through hole 64, the position regulating portion 145b abuts against the guide through hole 64. A tapered portion 145c whose width decreases toward the front end side of the press-fit terminal 145 is provided at the front end portion of the position restricting portion 145b. That is, the tip end portion of the position regulating portion 145b is tapered toward the tip end of the press-fit terminal 145. The inclination angle of the tapered portion 145c with respect to the front end surface of the position regulating portion 145b is, for example, in the range of 10 ° to 45 °.

A method for manufacturing the circuit connection device 2 according to embodiment 2 will be described. As in embodiment 1, the method of manufacturing the circuit connection device 2 according to embodiment 2 includes a first step of mounting the terminal arrangement member 6 on the circuit board 3, a second step of mounting the circuit board 3 and the terminal arrangement member 6 on the heat sink 5, and a third step of mounting the connector 104 on the heat sink 5. The first step and the second step are the same as those of embodiment 1, and therefore, the description thereof is omitted here.

In the third step, the circuit board 3, the terminal arrangement member 6, and the heat sink 5 fixed to each other in the second step are vertically reversed, and the circuit board 3, the terminal arrangement member 6, and the heat sink 5 are disposed so that the second surface 5b of the main body 50 is on the upper side. The connector 104 is disposed such that the second surface 5b of the main body 50 is opposite to the first surface 4a of the main body 40. The first positioning protrusion 46 of the connector 104 is inserted into the radiator-side through hole 56 of the radiator 5. By inserting the first positioning protrusion 46 into the heat sink-side through hole 56, the horizontal positions of the connector 104 with respect to the heat sink 5, the circuit board 3, and the terminal arrangement member 6 are adjusted. Thus, the center of the press-fit terminal 145, the center of the terminal through-hole 37, and the center of the guide through-hole 64 are aligned in the horizontal direction so that the center of the press-fit terminal 145, the center of the terminal through-hole 37, and the center of the guide through-hole 64 are aligned.

In this state, the connector 4 is further moved toward the heat sink 5, and the press-fit terminal 145 is inserted into the guide through hole 64. When the insertion of the bonding terminal 145 is advanced, the position regulating portion 145b of the bonding terminal 145 is inserted into the guide through hole 64, and the position regulating portion 145b abuts against the guide through hole 64. Since the tapered portion 145c is formed in the position regulating portion 145b and the insertion guide hole 65 is formed in the guide through hole 64, even the position regulating portion 145b having a wide width can be smoothly inserted into the guide through hole 64. The position regulating portion 145b abuts against the guide through hole 64, thereby regulating the movement of the press-fit terminal 145 in the horizontal direction. This can more reliably guide the press-fit terminal 145 to the terminal through-hole 37, and can reliably and smoothly insert the press-fit terminal 145 (the press-fit portion 45 a) through the terminal through-hole 37.

Then, a load is applied to the connector 104 in a direction orthogonal to the second surface 4b of the connector 104, and the connector 104 is pressed into the heat sink 5. Thereby, the press-fit terminal 145 is pressed into the terminal through-hole 37 and fixed. The first positioning protrusion 46 is pressed into and fixed to the radiator-side through hole 56. Then, in a state where the connector 104 is pressed against the heat sink 5, the connector 104 is fixed to the heat sink 5 by screw tightening.

As described above, in the circuit connection device 2 according to embodiment 2, the press-fit terminal 145 includes the press-fit portion 45a of the press-fit terminal through hole 37 and the position regulating portion 145b which is wider than the press-fit portion 45a and abuts against the guide through hole 64.

The movement of the press-fit terminal 145 can be restricted by the position restricting portion 145b coming into contact with the guide through hole 64, and the press-fit terminal 145 can be more reliably guided to the terminal through hole 37. Therefore, the press-fit terminal 145 can be reliably and smoothly inserted into the guide through hole 37. In addition, the tip of the press-fit terminal 145 can be prevented from colliding with the guide through hole 64 or the terminal through hole 37, and buckling of the press-fit terminal 145 can be prevented more reliably.

Embodiment 3.

The circuit connection device 2 according to embodiment 3 will be described below with reference to the drawings. The same reference numerals are given to constituent elements having the same functions and actions as those of embodiment 1, and the description thereof will be omitted.

Fig. 15 is a perspective view of a connector 204 according to embodiment 3. Fig. 16 is a schematic cross-sectional view of the circuit connection device 2 according to embodiment 3.

The connector 204 according to embodiment 3 has a plurality of press-fit terminals 245 instead of the plurality of press-fit terminals 45. The terminal arrangement member 206 according to embodiment 3 has a guide through hole 264 instead of the guide through hole 64.

The press-fit terminal 245 includes a press-fit portion 45a, a first position restriction portion 245c, a stress relaxation portion 245d, and a second position restriction portion 245e. The bonding portion 45a, the first position regulating portion 245c, the stress relaxing portion 245d, and the second position regulating portion 245e are provided in this order from the tip end portion toward the base end side of the bonding terminal 245. A tapered portion whose width decreases toward the front end side of the press-fit terminal 245 is provided at the front end portion of the first position regulating portion 245 c. A tapered portion whose width decreases toward the front end side of the press-fit terminal 245 is provided at the front end portion of the second position regulating portion 245e. That is, the tip end portion of the first position regulating portion 245c and the tip end portion of the second position regulating portion 245e have a tapered shape toward the tip end of the bonding terminal 245.

The width (maximum width) of the first position regulating portion 245c and the width (maximum width) of the second position regulating portion 245e are larger than the width (maximum width) of the nip portion 45 a. The width of the first position regulating portion 245c is the same as the width of the second position regulating portion 245e. The width of the stress relaxation portion 245d is smaller than the width of the first position restriction portion 245c and the width of the second position restriction portion 245e.

The guide through hole 264 has an abutment portion 264a and an enlarged diameter portion 264b.

The abutment portion 264a is provided on the lower surface 6c side of the guide through hole 264. The inner diameter of the abutting portion 264a is slightly larger than the width (maximum width) of the first position regulating portion 245c and the width (maximum width) of the second position regulating portion 245 e. When the press-fit terminal 245 is inserted through the guide through hole 264, the first position regulating portion 245c and the second position regulating portion 245e come into contact with the contact portion 264 a.

The enlarged diameter portion 264b is provided on the first surface 6a side of the guide through hole 264. The expanded portion 264b has an inner diameter larger than that of the abutment portion 264 a. The enlarged diameter portion 264b has an inner diameter larger than the inner diameter of the terminal through hole 37. The inner diameter of the expanded portion 264b is larger than the width of the first position regulating portion 245c and the width of the second position regulating portion 245 e. When the press-fit terminal 245 is pressed into the terminal through hole 37, the first position regulating portion 245c is disposed inside the enlarged diameter portion 264b in a state of not abutting the enlarged diameter portion 264b (at a distance from the enlarged diameter portion 264 b).

A method for manufacturing the circuit connection device 2 according to embodiment 3 will be described. As in embodiment 1, the method of manufacturing the circuit connection device 2 according to embodiment 3 includes a first step of mounting the terminal arrangement member 206 on the circuit board 3, a second step of mounting the circuit board 3 and the terminal arrangement member 206 on the heat sink 5, and a third step of mounting the connector 204 on the heat sink 5. The first step and the second step are the same as those of embodiment 1, and therefore, the description thereof is omitted here.

In the third step, the circuit board 3, the terminal arrangement member 206, and the heat sink 5 fixed to each other in the second step are vertically reversed, and the circuit board 3, the terminal arrangement member 206, and the heat sink 5 are disposed so that the second surface 5b of the main body 50 is on the upper side. The connector 204 is arranged such that the second surface 5b of the main body 50 is opposite to the first surface 4a of the main body 40. The first positioning protrusion 46 of the connector 204 is inserted into the radiator-side through hole 56 of the radiator 5. By inserting the first positioning protrusion 46 into the heat sink-side through hole 56, the horizontal positions of the connector 204 with respect to the heat sink 5, the circuit board 3, and the terminal arrangement member 206 are adjusted. In addition, the positions of the press-fit terminals 245, the terminal through holes 37, and the guide through holes 264 in the horizontal direction are aligned so that the center of the press-fit terminals 245, the center of the terminal through holes 37, and the center of the guide through holes 264 coincide with each other.

In this state, the connector 204 is further moved toward the heat sink 5, and the press-fit terminal 245 is inserted into the guide through hole 264. When the insertion of the bonding terminal 245 is advanced, first, the first position restriction portion 245c of the bonding terminal 245 abuts against the abutment portion 264a, thereby restricting the movement of the bonding terminal 245 in the horizontal direction.

When the insertion of the press-fit terminal 245 is further advanced, the second position regulating portion 245e is brought into contact with the contact portion 264a, and the first position regulating portion 245c is disposed inside the enlarged diameter portion 264 b. In this state, a load is applied to the connector 204 in a direction orthogonal to the second surface 4b of the connector 204, and the connector 204 is pushed into the heat sink 5. Thereby, the press-fit terminal 245 is press-fitted and fixed in the terminal through hole 37. At this time, the stress generated when the press-fit terminal 245 is pressed into the terminal through hole 37 can be relaxed by the stress relaxing portion 245 d. The first positioning protrusion 46 is pressed into and fixed to the radiator-side through hole 56. Then, in a state where the connector 204 is pressed against the heat sink 5, the connector 204 is fixed to the heat sink 5 by screw tightening.

As described above, in the circuit connection device 2 according to embodiment 3, the bonding terminal 245 includes: a pressing portion 45a, the pressing portion 45a being pressed into the terminal through hole 37; first and second position regulating portions 245c, 245e, the first and second position regulating portions 245c, 245e having a width wider than the nip portion 45 a; and a stress relaxing portion 245d, wherein the stress relaxing portion 245d is arranged between the first position limiting portion 245c and the second position limiting portion 245e, and the width is narrower than the first position limiting portion 245c and the second position limiting portion 245 e. The guide through hole 264 has: an abutting portion 264a, the abutting portion 264a abutting against the second position regulating portion 245e when the pressing portion 45a is pressed into the terminal through hole 37; and an enlarged diameter portion 264b, wherein the enlarged diameter portion 264b has an inner diameter larger than that of the contact portion 264a, and the first position regulating portion 245c is disposed inside the press-fit portion 45a when the press-fit portion is pressed into the terminal through hole 37.

The first position regulating portion 245c and the second position regulating portion 245e are brought into contact with the contact portion 264a, so that the movement of the bonding terminal 145 can be regulated, and the bonding terminal 245 can be more reliably guided toward the terminal through hole 37. Therefore, the press-fit terminals 245 can be reliably and smoothly inserted into the terminal through-holes 37. In addition, the stress relaxing portion 245d can relax the stress generated when the press-fit terminal 245 is pressed into the terminal through hole 37. Accordingly, it is possible to prevent an excessive stress from being applied to the press-fit terminal 245. As a result, breakage of the press-fit terminal 245 can be prevented, and the connection quality between the press-fit terminal 245 and the terminal through-hole 37 can be improved.

Embodiment 4.

The circuit connection device 2 according to embodiment 4 will be described below with reference to the drawings. The same reference numerals are given to constituent elements having the same functions and actions as those of embodiment 1, and the description thereof will be omitted.

Fig. 17 is a perspective view of a connector 304 of the circuit connection device 2 according to embodiment 2. Fig. 18 is a top view of connector 304.

The connector 304 according to embodiment 4 has the fourth positioning protrusion 47 and the fifth positioning protrusion 48 instead of the pair of first positioning protrusions 46.

The fourth positioning protrusion 47 has a columnar column portion 47b and a plurality of (4 in the present embodiment) ribs 47a protruding from the column portion 47 b. The plurality of ribs 47a are arranged at equal intervals (in the present embodiment, 90 ° intervals) in the circumferential direction of the column portion 47 b. The rib 47a extends parallel to the axis of the post 47 b. The rib 47a is provided over the entire length of the fourth positioning protrusion 47. A tapered surface 47c is provided at the distal end of the rib 47a toward the distal end of the fourth positioning projection 47. That is, the tip end of the rib 47a is tapered toward the tip end of the fourth positioning protrusion 47. The maximum diameter of the fourth positioning protrusion 47 (i.e., the outer diameter of the fourth positioning protrusion 47 in the portion where the rib 47a is provided) is larger than the inner diameter of the circuit substrate-side through hole 38.

The fifth positioning protrusion 48 has a columnar column portion 48b and a plurality of (2 in the present embodiment) ribs 48a protruding from the column portion 48 b. The plurality of ribs 48a are arranged at equal intervals (180 ° intervals in the present embodiment) in the circumferential direction of the pillar portion 48 b. The rib 48a extends parallel to the axis of the post 48 b. The rib 48a is provided over the entire length of the fifth positioning protrusion 48. A tapered surface 48c is provided at the tip end of the rib 48a toward the tip end of the fifth positioning projection 48. That is, the tip end portion of the rib 48a is tapered toward the tip end of the fifth positioning protrusion 48. The maximum diameter of the fifth positioning protrusion 48 (i.e., the outer diameter of the fifth positioning protrusion 48 in the portion where the rib 48a is provided) is larger than the inner diameter of the circuit substrate-side through hole 38.

Next, a method for manufacturing the circuit connection device 2 according to embodiment 4 will be described. As in embodiment 1, the method of manufacturing the circuit connection device 2 according to embodiment 4 includes a first step of mounting the terminal arrangement member 6 on the circuit board 3, a second step of mounting the circuit board 3 and the terminal arrangement member 6 on the heat sink 5, and a third step of mounting the connector 304 on the heat sink 5. The first step and the second step are the same as those of embodiment 1, and therefore, the description thereof is omitted here.

In the third step, the circuit board 3, the terminal arrangement member 6, and the heat sink 5 fixed to each other in the second step are vertically reversed, and the circuit board 3, the terminal arrangement member 6, and the heat sink 5 are disposed so that the second surface 5b of the main body 50 is on the upper side. The connector 304 is arranged such that the second face 5b of the main body 50 is opposite to the first face 4a of the main body 40. The fourth positioning projection 47 and the fifth positioning projection 48 of the connector 304 are inserted into the radiator-side through hole 56 of the radiator 5. By inserting the fourth positioning projection 47 and the fifth positioning projection 48 into the heat sink-side through hole 56, the horizontal positions of the connector 304 with respect to the heat sink 5, the circuit board 3, and the terminal arrangement member 6 are adjusted.

In the present embodiment, the fourth positioning protrusion 47 has 4 ribs 47a. The fifth positioning protrusion 48 has 2 ribs 48a. By inserting the fourth positioning protrusion 47 into the circuit board-side through hole 38, the horizontal displacement of the connector 304 with respect to the heat sink 5 is restricted. Further, the fifth positioning protrusion 48 is inserted into the circuit board-side through hole 38, so that the rotation of the connector 304 with respect to the heat sink 5 about the fourth positioning protrusion 47 is restricted.

In this state, the connector 304 is further moved toward the heat sink 5, and the press-fit terminal 45 is inserted into the guide through hole 64. When the insertion of the press-fit terminal 45 is advanced, the press-fit terminal 45 is moved toward the circuit board 3 side while being guided along the guide through hole 64, and is inserted into the terminal through hole 37.

Then, a load is applied to the connector 304 in a direction orthogonal to the second surface 4b of the connector 304, and the connector 4 is pushed into the heat sink 5. Thereby, the press-fit terminal 45 is press-fitted and fixed in the terminal through hole 37. The fourth positioning projection 47 and the fifth positioning projection 48 are pressed into and fixed to the radiator-side through hole 56. The diameters of the ribs 47a, 48a of the fourth positioning projection 47 and the fifth positioning projection 48 are set so that the press-in load when the fourth positioning projection 47 and the fifth positioning projection 48 are press-fitted into the radiator-side through hole 56 is significantly lower than the press-in load when the press-fit terminal 45 is press-fitted into the terminal through hole 37. Then, in a state where the connector 304 is pressed against the heat sink 5, the connector 304 is fixed to the heat sink 5 by screw tightening.

Since the number of ribs 48a of the fifth positioning protrusion 48 is smaller than the number of ribs 47a of the fourth positioning protrusion 47, the connector 304 is not completely fixed to the heat sink 5 through the fifth positioning protrusion 48 and the circuit board side through hole 38. That is, play is generated between the fifth positioning protrusion 48 and the circuit board side through hole 38. Thus, even when a positional shift occurs between the fourth positioning protrusion 47, the fifth positioning protrusion 48, and the circuit board side through hole 38, the connector 304 can be prevented from floating.

The distal ends of the plurality of ribs 47a are tapered toward the distal ends of the fourth positioning projections 47, and the distal ends of the plurality of ribs 48a are tapered toward the distal ends of the fifth positioning projections 48. Thus, the fourth positioning projection 47 and the fifth positioning projection 48 can be easily inserted into the radiator-side through hole 56 and the circuit board-side through hole 38. Further, even if the ribs 47a and 48a are scraped off when the fourth positioning projection 47 and the fifth positioning projection 48 are pressed into the circuit board side through hole 38, the generation of foreign matter can be suppressed.

In the present embodiment, the structure in which the ribs are provided on the positioning projections 46 of the connector 4 has been described, but the ribs may be provided on the second positioning projections 61 and the third positioning projections 62 of the terminal arrangement member 6.

Specifically, one of the pair of second positioning protrusions 61 includes a third column portion and a plurality of third ribs protruding from the third column portion, and the other of the pair of second positioning protrusions 61 includes a fourth column portion and a plurality of fourth ribs protruding from the fourth column portion. The number of the third ribs is, for example, 4, and the number of the fourth ribs is, for example, 2. The tip portions of the third ribs and the tip portions of the fourth ribs are tapered toward the tip ends of the second positioning protrusions 61.

One of the pair of third positioning protrusions 62 includes a fifth pillar portion and a plurality of fifth ribs protruding from the fifth pillar portion, and the other of the pair of third positioning protrusions 62 includes a sixth pillar portion and a plurality of sixth ribs protruding from the sixth pillar portion. The number of the fifth ribs is, for example, 4, and the number of the sixth ribs is, for example, 2. The distal ends of the plurality of fifth ribs and the distal ends of the plurality of sixth ribs are tapered toward the distal ends of the third positioning protrusions 62.

The embodiments may be combined, or modified or omitted as appropriate.

For example, in the above embodiment, the first positioning protrusion 46 is formed on the connector 4, and the second positioning protrusion 61 and the third positioning protrusion 62 are formed on the terminal arrangement member 6. The second positioning recess is formed by the circuit board side through hole 38 penetrating the circuit board 3, and the first positioning recess and the third positioning recess are formed by the radiator side through hole 56 penetrating the radiator 5. However, the present disclosure is not limited thereto. The first positioning protrusion may be formed on the heat sink 5, and the first positioning recess may be formed on the connector 4. The second positioning protrusion may be formed on the circuit board 3, and the second positioning recess may be formed on the terminal arrangement member 6. The third positioning protrusion may be formed on the heat sink 5, and the third positioning recess may be formed on the terminal arrangement member 6.

In the above embodiment, the pressing terminals 45 are pressed into the terminal through-holes 37 and fixed by applying a load to the circuit board 3 and pressing the circuit board 3 into the heat sink 5. However, depending on the type of the press-fit terminal 45, the press-fit terminal 45 may be pressed against the terminal through-hole 37 by applying an axial pressure to the press-fit terminal 45 from the tip of the press-fit terminal 45 to expand the width of the press-fit portion 45 a.

In the above embodiment, the electronic component is mounted on the first surface 3a of the circuit board 3, which is the surface on the output side of the rotary shaft 11. However, the present disclosure is not limited to this, and an electronic component may be mounted on the second surface 3b, which is a surface of the rotation shaft 11 on the non-output side. The heat dissipation lubricant 52 may be filled not only between the heat generating component 35 and the heat dissipation portion 51, but also in the whole between the circuit board 3 and the heat sink 5.

The number of the plurality of ribs 47a is not limited to 4, and the number of the plurality of ribs 48a is not limited to 2. The number of the plurality of ribs 47a and the number of the plurality of ribs 48a may be the same.

The circuit connection device 2 is not limited to the rotating electrical machine device a, and may be applied to an inverter device, a DC-DC converter device, a microcomputer application control device, and the like.

Description of the reference numerals

1 … rotary electric machine, 2 … circuit connection device, 3 … circuit board, 4, 104, 204, 304 … connector, 5 … heat sink, 6, 206 … terminal arrangement member, 37 … terminal through hole, 38 … circuit board side through hole (second positioning recess), 41 … power terminal (connection terminal), 42 … signal terminal (connection terminal), 45, 145, 245 … press-fit terminal, 45a … press-fit portion, 46 … first positioning protrusion portion, 47 … fourth positioning protrusion portion (one of a pair of first positioning protrusion portions), 47a … rib (first rib), 47b … column portion (first column portion), 48 … fifth positioning protrusion portion (the other of a pair of first positioning protrusion portions), 48a … rib (second positioning recess portion), 48b … column portion (second column portion), 55 … opening portion, 56 … radiator side through hole (first positioning recess portion, third positioning recess portion), 61 b … third positioning protrusion portion, 62 b positioning protrusion portion, and 245c restricting the position of the second positioning protrusion portion, 45b … column portion (first column portion), 48b … fifth positioning protrusion portion (second positioning protrusion portion 264), 55 a … column portion, and 45b … opening portion.

Claims

1. A circuit connection device, comprising:

a connector having a connection terminal connected to the outside and a press-fit terminal connected to the connection terminal;

a circuit board having a terminal through hole pressed into the press-fit terminal;

a terminal arrangement member which is arranged between the connector and the circuit board, is fixed to the circuit board, and has a terminal guide portion formed with a guide through hole for guiding the press-fit terminal to the terminal through hole; and

a heat sink to which the circuit board is fixed to a first surface, the connector is fixed to a second surface opposite to the first surface, the heat sink has an opening that penetrates from the first surface to the second surface and accommodates the terminal guide portion therein,

a first positioning protrusion is formed on one of the connector and the heat sink, a first positioning recess is formed on the other of the connector and the heat sink, the first positioning recess being fitted to the first positioning protrusion,

a second positioning protrusion is formed on one of the circuit board and the terminal arrangement member, a second positioning recess is formed on the other of the circuit board and the terminal arrangement member, the second positioning recess being fitted with the second positioning protrusion,

A third positioning protrusion is formed on one of the heat sink and the terminal arrangement member, and a third positioning recess is formed on the other of the heat sink and the terminal arrangement member, the third positioning recess being fitted to the third positioning protrusion.

2. The circuit connection device of claim 1, wherein,

the first positioning protrusion is formed on the connector so as to extend parallel to the press-fit terminal,

the second positioning protrusion and the third positioning protrusion are formed on the terminal arrangement member,

the second positioning recess is a circuit board side through hole formed so as to penetrate the circuit board,

the first positioning recess and the third positioning recess are radiator-side through holes formed so as to penetrate the radiator.

3. The circuit connection device of claim 2, wherein,

the length of the press-fit terminal in the extending direction from the tip end of the first positioning protrusion to the opening end of the connector side of the heat sink side through hole is longer than the length of the press-fit terminal in the extending direction from the tip end of the press-fit terminal to the opening end of the connector side of the guide through hole.

4. A circuit connection device according to any one of claims 1 to 3,

the press-fit terminal has a press-fit portion press-fitted into the terminal through-hole, and a position regulating portion having a width wider than the press-fit portion and abutting the guide through-hole.

5. A circuit connection device according to any one of claims 1 to 3,

the press-fit terminal has a press-fit portion press-fitted into the through hole for the terminal, a first position regulating portion and a second position regulating portion having a width wider than the press-fit portion, and a stress relaxing portion provided between the first position regulating portion and the second position regulating portion and having a width narrower than the first position regulating portion and the second position regulating portion,

the guide through hole has an abutting portion abutting against the second position regulating portion when the pressing portion is pressed into the terminal through hole, and an expanded diameter portion having an inner diameter larger than that of the abutting portion and having the first position regulating portion disposed inside the pressing portion when the pressing portion is pressed into the terminal through hole.

6. The circuit connection device of claim 2, wherein,

the connector is formed with a pair of first positioning protrusions including the first positioning protrusion,

The pair of first positioning protrusions are provided so as to sandwich the press-fit terminal.

7. The circuit connection device of claim 6, wherein,

one of the pair of first positioning protrusions has a first column portion and a plurality of first ribs protruding from the first column portion,

the other of the pair of first positioning protrusions has a second column portion and a plurality of second ribs protruding from the second column portion,

the number of the plurality of second ribs is smaller than the number of the plurality of first ribs.

8. The circuit connection device of claim 7, wherein,

the distal ends of the plurality of first ribs and the distal ends of the plurality of second ribs are tapered toward the distal ends of the first positioning protrusions.

9. The circuit connection device of claim 2, wherein,

the terminal arrangement member is formed with a pair of second positioning projections including the second positioning projection,

the pair of second positioning protrusions are provided so as to sandwich the guide through hole.

10. The circuit connection device of claim 9, wherein,

One of the pair of second positioning protrusions has a third column portion and a plurality of third ribs protruding from the third column portion,

the other of the pair of second positioning protrusions has a fourth column portion and a plurality of fourth ribs protruding from the fourth column portion,

the number of the fourth ribs is smaller than the number of the third ribs.

11. The circuit connection device of claim 10, wherein,

the distal ends of the plurality of third ribs and the distal ends of the plurality of fourth ribs are tapered toward the distal ends of the second positioning protrusions.

12. The circuit connection device of claim 2, wherein,

the terminal arrangement member is formed with a pair of third positioning protrusions including the third positioning protrusion,

the pair of third positioning protrusions are provided so as to sandwich the guide through hole.

13. The circuit connection device of claim 12, wherein,

one of the pair of third positioning protrusions has a fifth pillar portion and a plurality of fifth ribs protruding from the fifth pillar portion,

the other of the pair of third positioning protrusions has a sixth column portion and a plurality of sixth ribs protruding from the sixth column portion,

The number of the sixth ribs is smaller than the number of the fifth ribs.

14. The circuit connection device of claim 13, wherein,

the distal ends of the plurality of fifth ribs and the distal ends of the plurality of sixth ribs are tapered toward the distal ends of the third positioning protrusions.

15. The circuit connection device according to any one of claims 1 to 14, wherein,

the circuit board is screwed to the heat sink.

16. The circuit connection device according to any one of claims 1 to 15, wherein,

the connector is screwed to the heat sink.

17. A rotating electrical machine apparatus, comprising:

a rotating electric machine; and

the circuit connection device according to any one of claims 1 to 16, which controls the rotating electrical machine.

18. A method of manufacturing a circuit connection device, the circuit connection device comprising: a connector having a connection terminal connected to the outside and a press-fit terminal connected to the connection terminal; a circuit board having a terminal through hole pressed into the press-fit terminal; a terminal arrangement member which is arranged between the connector and the circuit board, is fixed to the circuit board, and has a terminal guide portion formed with a guide through hole for guiding the press-fit terminal to the terminal through hole; and a heat sink to which the circuit board is fixed on a first surface, the connector is fixed on a second surface opposite to the first surface, the heat sink has an opening that penetrates from the first surface to the second surface and accommodates the terminal guide portion therein, a first positioning protrusion is formed on one of the connector and the heat sink, a first positioning recess that fits into the first positioning protrusion is formed on the other of the connector and the heat sink, a second positioning protrusion is formed on one of the circuit board and the terminal arrangement member, a second positioning recess that fits into the second positioning protrusion is formed on the other of the circuit board and the terminal arrangement member, a third positioning protrusion is formed on one of the heat sink and the terminal arrangement member, and a third positioning recess that fits into the third positioning protrusion is formed on the other of the heat sink and the terminal arrangement member, the manufacturing method of the circuit connection device includes:

A first step of fixing the terminal arrangement member to the circuit board by fitting the second positioning protrusion into the second positioning recess;

a second step of fitting the third positioning protrusion and the third positioning recess, accommodating the terminal guide in the opening, and fixing the terminal arrangement member to the heat sink; and

and a third step of fitting the first positioning protrusion and the first positioning recess, inserting the press-fit terminal into the guide through hole, and pressing the terminal through hole, thereby fixing the connector to the heat sink.